Technical Information

Rev. 3, Nov. 2002

Types, Properties and Uses of Hypalon

Hypalon is the registered trademark for a series of
chlorosulfonated polyethylene synthetic rubbers
manufactured by DuPont Dow Elastomers. Vulcanizates of Hypalon are highly resistant to the deteriorating effects of ozone, oxygen, weather, heat, oil and
chemicals. Hypalon resists discoloration on exposure
to light, and is widely used in light-colored vulcanizates. It can be compounded to give excellent
mechanical propertiesfor example, high tensile
strength and abrasion resistance.

Toxicology Program (NTP), and the American

Conference of Governmental Industrial Hygienists
(ACGIH) as substances for which there is limited
evidence of carcinogenicity to humans. Under the
Occupational Safety and Health Act (OSHA), exposures to carbon tetrachloride must be kept below the
permissible exposure limit of 10 ppm and chloroform
must be kept below the permissible exposure limit of
50 ppm. When large quantities of raw polymer are
stored or processed in enclosed areas with restricted
air exchange or ventilation, the air must be monitored
for carbon tetrachloride and chloroform; and, if
necessary, ventilation must be supplied to comply with
OSHA regulations.

Several types and grades of Hypalon are available

for a variety of end use requirements. A general
description of each of these products is shown in
Table 1, and additional details are given in other
sections of this technical bulletin. All of these types
may be processed and used in the usual manner for
solid elastomeric vulcanizates. However, several
types are also of value in two additional areas
unvulcanized applications and solution coating
applications.

For additional information concerning this and other

potential industrial health hazards when handling
Hypalon, see DuPont Dow Elastomers technical
bulletin, Toxicity and Handling Guide, and the
Material Safety Data Sheet (MSDS).

Compounding Ingredients

When compounding with Hypalon, proper selection

of polymer type is the starting point for a suitable
finished product. Equally important is the selection
of the other compounding ingredients. A general
outline of compounding ingredients and their functions
(arranged in alphabetical order) is shown.

Compounding ingredients, including peroxides and

lead-based curatives, used with Hypalon to prepare
finished products, may present hazards in handling
and use. Before proceeding with any compounding
or processing work, consult and follow label directions
and handling precautions from suppliers of all
ingredients.

This technical bulletin is intended as a brief guide to

selection of the most suitable type of Hypalonthe
first step in developing a practical, serviceable compound to meet the requirements of a particular
application.

Waste Disposal

Handling Precautions for Hypalon

Safe Handling
Hypalon synthetic rubber contains low levels of
carbon tetrachloride (CCl4) and chloroform (CHCl3)
as residues from manufacturing. Carbon tetrachloride
and chloroform are classified by The International
Agency for Research on Cancer (IARC), the National
1

All grades of Hypalon raw polymer exceed the

regulated maximum leachate level for carbon tetrachloride in the U.S. Environmental Protection Agency
(EPA) toxicity characteristic leaching procedure
(TCLP test); therefore, discarded polymer should be
considered a Resource Conservation and Recovery
Act (RCRA) hazardous waste by anyone who
generates more than 220 lb of total hazardous waste
(includes waste from all sources) at a site in a calendar month.

Table 1
Description of Types of Hypalon

Description
Chlorine Content, %
Sulfur Content, %
Physical Form
Color
Odor
Specific Gravity
Mooney Viscosity,
ML 1 + 4 at 100C
Storage Stability
Distinguishing
Features

20

30

45

6525

29
1.4
Chips
White
None
1.12

43
1.1
Chips
White
None
1.27

24
1.0
Chips
White
None
1.07

27
1.0
Chips
White
None
1.10

28
Excellent

30
Excellent

37
Excellent

90
Excellent

Readily
soluble in
common
solvents.
Good lowtemperature
flexibility.

Readily
soluble in
common
solvents.
Forms hard,
glossy films.

High
uncured
strength.
Good heat
resistance.
Good lowtemperature
flexibility.

High
polymer
viscosity.
Good lowtemperature
and heat
resistance.
Good
processing
at high
extensions

Fair
Good
Fair

Fair
Fair
Fair

Good
Excellent
Excellent

Excellent
Excellent
Good

1,300
9

400
4

60

45

4595

6095

6598

4095

Up to 20
Up to 8
Excellent
Good
Fair

Up to 24
Up to 17
Excellent
Poor
Fair

Up to 27
Up to 27
Excellent
Excellent
Good

Up to 27
Up to 27
Excellent
Excellent
Good

Very Good
Good
Fair
Fair
Very Good
Excellent
Fair
Excellent

Very Good
Excellent
Poor
Very Good
Fair
Excellent
Excellent
Excellent

Excellent
Good
Good
Fair
Very Good
Excellent
Fair
Excellent

Excellent
Very Good
Very Good
Fair
Very Good
Excellent
Fair
Excellent

Processing Characteristics
Extruding
Molding
Calendering
Solution Properties
Brookfield Viscosity, MPas
25 wt% Polymer in Toluene
5 wt% Polymer in Xylene
Vulcanizate Properties
Hardness, Durometer A
Tensile Strength, MPa
Carbon Black Stocks
Gum Stocks
Color Stability
Low-Temperature Properties
Tear Strength
Resistance to
Abrasion
Chemicals
Compression Set
Flame
Heat-Aging
Ozone
Petroleum Oils
Weathering

Note: All values on this table are approximate. They are presented to describe the various products,
and are not intended to serve as specifications.

(continued)

Table 1 (continued)
Description of Types of Hypalon

Description
Chlorine Content, %
Sulfur Content, %
Physical Form
Color
Odor
Specific Gravity
Mooney Viscosity,
ML 1 + 4 at 100C
Storage Stability
Distinguishing
Features

40S

40

4085

48

35
1.0
Chips
White
None
1.18

35
1.0
Chips
White
None
1.18

36
1.0
Chips
White
None
1.19

43
1.0
Chips
White
None
1.27

46
Excellent

56
Excellent

94
Excellent

78
Excellent

Low polymer
viscosity.
Improves
processing
of dry,
stiff stocks.

Medium
polymer
viscosity.
Versatile,
suitable for
many
applications.

High
polymer
viscosity.
Good green
strength.
Improves
processing
of soft or
highly extended
stocks.

High
polymer
viscosity.
Excellent
oil and
fluids
resistance.
High
uncured
strength.

Excellent
Excellent
Excellent

Excellent
Excellent
Excellent

Excellent
Excellent
Excellent

Good
Good
Good

20

25

50

12

4095

4095

4095

6095

Up to 27
Up to 27
Excellent
Good
Good

Up to 27
Up to 27
Excellent
Good
Good

Up to 27
Up to 27
Excellent
Good
Good

Up to 27
Up to 24
Excellent
Poor
Good

Excellent
Excellent
Good
Good
Very Good
Excellent
Good
Excellent

Excellent
Excellent
Good
Good
Very Good
Excellent
Good
Excellent

Excellent
Excellent
Good
Good
Very Good
Excellent
Good
Excellent

Excellent
Excellent
FairGood
Very Good
Good
Excellent
Excellent
Excellent

Processing Characteristics
Extruding
Molding
Calendering
Solution Properties
Brookfield Viscosity, MPas
25 wt% Polymer in Toluene
5 wt% Polymer in Xylene
Vulcanizate Properties
Hardness, Durometer A
Tensile Strength, MPa
Carbon Black Stocks
Gum Stocks
Color Stability
Low-Temperature Properties
Tear Strength
Resistance to
Abrasion
Chemicals
Compression Set
Flame
Heat-Aging
Ozone
Petroleum Oils
Weathering

Note: All values on this table are approximate. They are presented to describe the various products, and are not intended to serve as specifications.

 Heat resistance to 150C

Resistance to a wide range of aggressive chemicals
Intermediate oil and solvent resistance depending
on the chlorine level
Electrical insulating properties
Low flammability characteristics
(associated with chlorinated polymers)
Excellent resistance to abrasion and mechanical
abuse

The level of residual carbon tetrachloride in compounds is less than in Hypalon because of dilution by
other ingredients in the compound. Compounding
ingredients, processes, and applications vary significantly, so you will need to reach your own conclusions
as to whether waste generated by your process
exceeds TCLP regulatory limits subject to RCRA
regulations.
Hypalon contains no lead, but lead containing materials are sometimes compounded with it. If lead can be
extracted from the compound in amounts that exceed
the regulatory limit of EPAs TCLP test, then the
compounded waste is a RCRA hazardous waste
(Federal Register, 3/29/90, p 11862; 40CFR261.24),
and must be handled as such. The amount of lead
extracted in the TCLP test will depend on the amount
and type of lead compound present, other compounding ingredients, and compounding and/or curing
conditions. If you have any questions, please contact
your DuPont Dow Elastomers sales representative.

The following are areas of application where

Hypalon is the preferred polymer.
Hypalon is used in the hose industry whenever its
specific properties are required. Thus, it is used in
power steering and oil cooler hoses for automotive
and industrial hydraulic hose, where impulse testing is
performed up to 150C. Hypalon is also widely used
for fuel hose covers and various vacuum and emission
tubing applications.
Hypalon is used widely as a sheathing material for
cable constructions. It is often specificed in this
application for resistance to weathering, sunlight,
ozone, and heat.

General Characteristics and Uses of

Hypalon
Hypalon is the trademark assigned to a group of
sulfur and peroxide curable elastomers that are based
on chlorosulfonated and chlorinated polyethylene.
These polymers are manufactured in such a manner
as to produce an elastomer with a completely saturated backbone and pendant groups suitable for varied
approaches to vulcanization. As a result of this
configuration, vulcanizates of Hypalon synthetic
rubber are extremely resistant to attack by ozone,
oxygen and weather. In addition, properly prepared
vulcanizates of Hypalon are outstanding in resistance
to deterioration by heat, oils, and many chemicals and
fluids.

Certain grades of Hypalon are used to produce a

single-ply roofing system. This is white in color for
heat reflectance while possessing good water,
weather, and UV light resistance. The same technology with Hypalon is used to produce fabric reinforced, heat weldable linings for reservoirs and
effluent pits. Hypalon liners are noted for their
resistance to oils as well as chemicals.
Roll covers resist a large variety of chemicals and
solvents over a wide range of temperatures. While
possessing good resilience and resistance to wear,
Hypalon has all these characteristics and is one of
the most commonly used polymers in this field.

Hypalon is used in the rubber industry because of its

wide range of unique properties. The properties may
be summarized as:
Permanent bright colors
Superb ozone and weather resistance, even in nonblack products

Hypalon coatings, both rigid and flexible, are used in

many fields to provide resistance to weather, chemicals, oils and solvents while maintaining an attractive
colored appearance.

Selecting the Type of Hypalon

However, there are chemical and physical differences

between the various types which affect processibility
and properties. The compounder must select the type
that will best produce the desired end-product.

All of the available types of Hypalon synthetic

rubber, when properly compounded and cured,
possess the basic characteristics for which Hypalon
is knowngood rubberlike mechanical properties
and excellent resistance to the deteriorating effects of
oxygen, ozone, weather, heat, oils and chemicals.

The principal features of each type are summarized in

Figure 1 and described more fully in the text.

Figure 1. Selection Guide for Hypalon

Hypalon 48
Better oil resistance.
Higher modulus.
Higher hardness.
Good uncured
properties.

Hypalon 6525
For highly extended
compoundslower
cost vulcanizates.
Better heat and lowtemperature performance.

Hypalon 45
Excellent uncured
properties.
Better low-temperature
flexibility.
Higher hardness.
Better tear strength.
Better heat resistance.

Specialty Types
for
Solution Applications

Hypalon 4085
for highly extended
compounds,
lower durometer
vulcanizates

Hypalon 40
Basic general purpose type
Good oil resistance
Good heat resistance
Good low-temperature properties

Hypalon 40S
(Soft) for lightly
plasticized compounds,
higher durometer
vulcanizates

Hypalon 20
For flexible substrates
Good low-temperature
flexibility

Hypalon 30
For rigid substrates
Hard, glossy films.
Good oil resistance

Hypalon 48
Hard, glossy films.
Good oil resistance.
Somewhat better
low-temperature
properties than
Hypalon 30.

General Purpose Types

Specialty Types for Solution

Applications

Hypalon 40 synthetic rubber is considered the basic

general purpose chlorosulfonated polyethylene elastomer, having a good balance of processibility and
vulcanizate properties. It provides good oil and chemical resistance and intermediate low-temperature
performance.

Hypalon 20 and Hypalon 30 are suitable primarily

for solution applications. They are more readily soluble
in organic solvents than are the other types and can be
formulated to yield solutions having relatively low
viscosity at high solids content.

Higher and lower viscosity grades of Hypalon 40 are

available to provide a range of compounding and
processing capability within the general purpose
family. Hypalon 4085 is a higher viscosity grade,
which offers improved processibility and dilutability for
highly extended formulations, or low durometer
vulcanizates. On the lower end of the viscosity range
is Hypalon 40S (soft). This polymer provides easier
processing in lightly-plasticized, higher durometer
compounds.

Solutions of compounds of Hypalon are used for

coating fabrics, fluid applied roofing, decorative and
ozone-proof coatings for elastomeric articles, and as
chemical resistant maintenance coatings.
Hypalon 20 yields films that are more flexible and
extensible at low temperatures than Hypalon 30. On
the other hand, films of Hypalon 30 are more oil and
chemical resistant, harder, and glossier than films of
Hypalon 20.
Hypalon 20 or Hypalon 30 can be used to prepare
dry rubber compounds, but they are more difficult to
process than the general purpose types and yield
vulcanizates having poorer mechanical properties.

Specialty Types for Dry Applications

Hypalon 45 is more thermoplastic than Hypalon 40;
it has a lower viscosity at processing temperature, but
gives better room temperature green strength and
harder vulcanizates. Hypalon 45 has a lower chlorine
content than does Hypalon 40; therefore, it is more
flexible at low temperatures, but has reduced oil and
fuel resistance. It also provides higher modulus and
better heat resistance than the general purpose types.

Hypalon 48 also finds some use in solution applications, primarily because of its good oil and chemical
resistance. Solution viscosity is generally higher than
that of Hypalon 20 or Hypalon 30 at the same solids
content. Film characteristics are similar to those of
Hypalon 30, except that the films are somewhat more
extensible at low temperatures.

Hypalon 45 can be compounded to give very good

mechanical properties in uncured stocks. It is frequently used uncured in sheeting applications because
of its strength and ease of seaming.

Vulcanizate Properties
Hypalon 40 synthetic rubber gives an excellent
combination of vulanizate properties. Hypalon 40S
and Hypalon 4085 offer a similar balance of properties while broadening the range of compound viscosities to meet most processing needs.

Hypalon 6525 is a high viscosity, extensible polymer

with some characteristics similar to Hypalon 45. It
has a lower chlorine content than Hypalon 40, which
yields compounds with excellent low-temperature
properties and slightly improved oven aging performance. It can be compounded for lower cost because
it can accept high filler loadings and can use less
expensive plasticizers. Some decrease in oil and flame
resistance is to be expected.

Gum Vulcanizates
Gum vulcanizates of Hypalon 40 and its viscosity
variants have excellent tensile strength. Therefore, the
use of highly reinforcing fillers to obtain high quality
vulcanizates is not necessary (See Table 2). Hypalon
45 gives higher modulus, tear strength, and hardness
as compared with the Hypalon 40 and Hypalon 48
types. Hypalon 30 also gives a gum vulcanizate with
high modulus and hardness, but lower tensile strength.
The gum tensile strength of Hypalon 20 is very low
and therefore, to achieve high quality vulcanizates,
highly reinforcing fillers must be used.

Hypalon 48 is intermediate in thermoplasticity

between Hypalon 40 and Hypalon 45. It provides
better oil resistance, but poorer low temperature
properties than Hypalon 40 (or Hypalon 45). It also
has very high resistance to permeation by some
refrigerants and other gases.
Hypalon 48 can be compounded for good uncured
properties, but not as good as those of uncured
compounds of Hypalon 45. Hypalon 48 will impart
greater oil and flame resistance than Hypalon 45 in
comparable compositions, at a sacrifice in low temperature flexibility.

Carbon Black Filled Vulcanizates

Mineral Filled Vulcanizates

A comparison of the various types of Hypalon in a

carbon black filled stock (Tables 3 and 4), shows the
good balance of properties obtainable with Hypalon
40. Hypalon 4085, and Hypalon 6525 give higher
modulus, tensile strength, and hot physical properties.
Hypalon 30 gives high hardness with low compound
viscosity. Hypalon 30 and 48 have the best resistance to oil. The good oil and fluid resistance of
Hypalon 48 are further illustrated in Table 5.

A similar comparison, in a mineral filled stock is

shown in Table 6. Note that Hypalon 4085, besides
giving high compound viscosity, gives high modulus
and tensile strength, and good hot properties. The
higher hardness of Hypalon 45 at this low loading
level allows the formulation of easy processing, high
durometer stocks. Hypalon 30 and 48 give maximum
resistance to oil, with Hypalon 48 providing better
physical and low-temperature properties.

Table 2
Properties of Gum Compounds
Hypalon (grades below)
Magnesia (high activity)a
Pentaerythritol (200 mesh)b
Tetrone A
Type of Hypalon

100
4
3
2
20

30

40

4085

45

48

Mooney Viscosity,
ML 1 + 4 at 100C

34

37

62

96

45

87

Mooney Scorch, MS at 121C

Minimum Viscosity, units
Time to 10-unit rise, min

11
25

9
41

18
35+

30
29

14
35+

23
45

Original Physicals
100% Modulus, MPa
300% Modulus, MPa
Tensile Strength, MPa
Elongation, %
Hardness, Durometer A

1.8

8.3
280
54

2.8
12.4
18.3
400
69

1.0
4.2
28.1
520
53

1.4
5.2
31.0
550
54

3.0
6.9
24.6
480
80

1.4
6.7
31.7
490
60

Tear Strength, Die C

kN/m

41.1

28.0

28.0

31.5

37.2

28.9

Stock Properties

Vulcanizate Properties
Cured: Time 30 min at 153C

Maglite D was used

Hercules PE-200 was used

Table 3
Properties of Black Filled Compounds
Hypalon (grades below)
N762 Carbon Black
Aromatic Process Oil
LMW Polyethylene Process Aid
Magnesium Oxide
Pentaerythritol
Tetrone A
MBTS
Type of Hypalon

100
60
25
2
5
3
2
0.5
40S

40

4085

6525

45

48

30

20

Mooney Viscosity,
ML 1 + 4 at 100C

49

52

88

82

39

60

33

30

Mooney Scorch, MS at 125C

Minimum Viscosity, units
Time to 10-pt rise, min.

14
14

16
13

28
12

30
13

13
13

16
13

7
9

9
11

10.8

10.2

10.0

7.6

12.8

18.1

19.1

20

20

20

20

20

20

30

30

Original Physicals at 23C

50% Modulus, MPa
100% Modulus, MPa
200% Modulus, MPa
Tensile Strength, MPa
Elongation, %
Hardness, Shore A

2.5
6.5
16.2
20.5
292
70

2.3
6.2
16.4
21.3
287
67

3.0
8.1
20.0
23.7
270
72

2.8
7.4
18.9
24.1
275
68

4.5
8.1
16.6
20.0
266
83

4.1
10.1
19.6
21.0
253
78

6.9
15.0

18.5
152
84

3.8
9.6

14.9
147
70

Oven Aged 168 hr at 125C

Change in 50% Modulus, %
Change in Tensile Strength, %
Change in Elongation, %
Change in Hardness, pts

169
11
42
12

184
6
44
14

219
10
42
12

95
4
23
12

86
0
40
7

219
18
49
12

197
25
58
12

137
10
40
13

Volume Change, %
IRM903 Oil, 168 hr at 125C
Distilled Water, 168 hr at 70C

61
28

64
24

41
28

99
23

150
22

30
30

21
34

90
32

Compression Set, Method B

22 hr at 100C, % set

67

65

59

55

63

80

86

74

Tear Strength, Die C

kN/m

38

38

42

42

44

35

27

25

Low Temperature Properties

DSC-Tg, C
Brittle Point, C

21
28

22
32

17
30

27
42

24
44

0
16

7
8

26
26

DIN Abrasion
Abrasion Index

118

112

110

99

154

148

243

154

Stock Properties

MDR at 160C, 0.5 arc, 30-min chart

Tc-90, min
11.6
Vulcanizate Properties
Cure Time at 160C

Table 4
Properties of Peroxide Cured Black Filled Compounds
Hypalon (grades below)
Magnesia (high-activity)
N774 Carbon Black
Varox DBPH50

100
20
40
5.8

Type of Hypalon

45

20

30

48

40S

40

4085

Mooney Scorch, MS at 135C

Minimum Viscosity, units
Points rise at 30 min

43
9

36
9

34
1

51
0

42
2

50
2

81
3

ODR, 30 min at 177C

ML, N-m
MH, N-m
ts2, min
tc90, min

1.4
6.3
1.1
8.5

0.9
3.0
1.9
11.0

0.7
2.2
3.2
21.2

1.5
4.2
2.0
19.5

1.4
5.1
1.6
13.0

1.6
5.6
1.3
13.2

1.5
6.4
1.4
14.6

Original Physicals
200% Modulus, MPa
Tensile Strength, MPa
Elongation, %
Hardness, Durometer A

17.8
18.5
210
87

10.4
12.2
255
71

12.6
13.6
185
83

18.1
19.3
275
84

14.8
19.2
270
76

15.8
19.1
250
76

18.9
22.3
240
77

Aged 70 hr at 100C
Tensile, % change
Elongation, % change
Hardness change, pts

4
10
5

13
8
9

42
43
12

28
33
6

12
13
8

11
15
6

9
14
6

Aged 70 hr at 149C
Tensile, % change
Elongation, % change
Hardness change, pts

21
39
3

0
72
15

46
91
18

9
88
10

31
79
10

28
78
13

26
72
10

Aged 70 hr at 121C in IRM903 Oil

Tensile, % change
Elongation, % change
Hardness change, pts
% Volume Increase

51
43
33
101

55
52
30
114

17
10
16
36

6
17
15
35

27
29
24
68

32
35
24
68

33
30
21
60

Compression Set, Method B, %

22 hr at 100C

21

35

47

28

27

24

Stock Properties

Vulcanizate Properties

Table 5
Fluid Resistance of Hypalon
Base Compound No.
Hypalon (grade as shown)
N762 Carbon Black
Atomite Whiting
TOTM Plasticizer
Vanwax H
LMW Polyethylene Process Aid
HVA-2
MBTS
NBC
Tetrone A
Magnesium Oxide
Pentaerythritol
Hydrotalcite (Kyowa DHT-4A)
Total Parts

1
100
40
40
25
2
2
1
1
2
1
5
3

2
100
40
40
25
2
2
1
1
2
1
20
234

222

Hypalon Type
Compound No.

4085
1

4085
2

45
1

45
2

48
1

48
2

Mooney Scorch, MS at 125C

Minimum Viscosity, MU
Time to 5 pt rise, min

20.7
12.8

23.0
12.3

10.3
16.1

11.8
16.2

11.0
13.6

11.9
15.0

25

20

25

30

30

20

3.7
8.1
16.9
363
61

4.3
10.7
17.1
299
65

5.3
8.2
12.6
342
82

5.4
9.1
12.7
282
83

4.3
8.2
14.4
376
67

5.0
10.9
15.6
280
72

1.3
13.2
31.9
58.5
6.9
0.8
17.7
0.5
43.9
156.7
3.5
2.7
86.9

1.9
11.2
24.2
49.9
7.8
0.5
11.7
1.9
2.5
45.2
1.9
2.8
101.6

Original Physical Properties at 23C

Cure Time at 160C, min
100% Modulus, MPa
200% Modulus, MPa
Tensile Strength, MPa
Elongation, %
Hardness, Shore A
Fluid Agings
Fluid
Dextron III
Diesel Fuel
Fuel B
Fuel C
Hydraulic Oil (Harmony 46)
ASTM IRM902 Oil
ASTM IRM903 Oil
Motor Oil5W30
50-50 Antifreeze Water
Distilled Water
50% Conc. Sodium Hydroxide
50% Conc. Sulfuric Acid
37% Conc. Hydrchoric Acid
Fluid
Dextron III
Diesel Fuel
Fuel B
Fuel C
Hydraulic Oil (Harmony 46)
ASTM IRM902 Oil
ASTM IRM903 Oil
Motor Oil5W30
50-50 Antifreeze Water
Distilled Water
50% Conc. Sodium Hydroxide
50% Conc. Sulfuric Acid
37% Conc. Hydrchoric Acid

Exposure Conditions
70 hr at 125C
70 hr at 50C
70 hr at 23C
70 hr at 23C
70 hr at 125C
70 hr at 125C
70 hr at 125C
70 hr at 125C
168 hr at 105C
70 hr at 100C
70 hr at 100C
70 hr at 100C
70 hr at 60C

Volume Change, %
13.2
25.7
37.3
85.0
1.8
16.7
40.7
12.0
33.3
89.7
2.9
2.8
71.0

Exposure Conditions
70 hr at 125C
70 hr at 50C
70 hr at 23C
70 hr at 23C
70 hr at 125C
70 hr at 125C
70 hr at 125C
70 hr at 125C
168 hr at 105C
70 hr at 100C
70 hr at 100C
70 hr at 100C
70 hr at 60C

9.5
21.8
34.0
66.0
0.3
13.2
31.3
7.9
1.9
25.7
1.6
2.7
99.3

88.2
83.5
56.0
118.9
58.5
77.5
114.2
91.4
29.1
91.0
4.1
2.6
83.9

56.9
64.9
54.2
100.4
37.5
55.8
80.3
53.5
2.5
22.2
2.8
2.9
90.7

Volume Change After Dryout*, %

10.6
3.4
12.9
13.8
1.2
15.5
30.7
8.7
13.8
25.0
10.4
0.05
18.8

*Dryout Time, 24 hr at 70C

10

6.6
5.1
12.8
14.3
1.2
12.3
22.5
4.9
1.0
1.3
11.9
0.04
31.9

82.3
10.1
17.9
18.9
55.3
76.0
95.7
82.5
11.1
23.4
13.8
0.12
22.1

52.5
11.5
17.5
18.2
36.6
55.3
66.3
48.9
0.8
0.5
14.3
0.21
31.5

0.2
3.0
6.5
10.4
6.8
0.4
14.6
1.3
20.4
55.6
6.3
0.34
21.8

3.2
2.3
8.4
10.8
7.7
1.2
8.4
3.7
0.8
5.4
8.1
0.19
36.6

Table 6
Properties of Mineral Filled Compounds
Hypalon (grades below)
Magnesia (high-activity)a
Hard Clayb
Aromatic Process Oilc
Pentaerythritol (200 mesh)d
Tetrone A
Type of Hypalon

100
4
80
30
3
2
20

30

40S

40

4085

6525

45

48

Mooney Viscosity,
ML 1 + 4 at 100C

16

15

40

44

73

83

26

37

Mooney Scorch, MS at 121C

Minimum Viscosity, units
Time to 10-unit rise, min

5
38

5
35

14
29

16
24

26
23

30
26

10
46

8
48

Physical Properties at 24C

100% Modulus, MPa
200% Modulus, MPa
Tensile Strength, MPa
Elongation, %
Hardness, Durometer A

5.6
8.4
9.4
260
63

12.4

14
140
82

5.5
7.8
18.6
550
63

6.0
8.4
19
550
67

6.0
9.0
20.7
520
69

5.3
7.9
20
530
70

5.0
7.4
18.8
540
81

6.2
11.8
16.8
470
72

Aged 7 days at 121C

Tensile Strength, MPa
Elongation, %
Hardness, Durometer A

15.8
120
74

21.8
80
91

16.2
200
76

17.0
210
78

17.9
205
78

15.4
270
78

15.2
250
84

18.6
180
80

Original Physicals at 100C

Tensile Strength, MPa
Elongation, %

3.8
150

3.0
90

2.8
210

3.1
220

3.7
215

4.0
215

3.0
270

4.4
280

Tear Strength, Die C, kN/m

31.6

26.8

55.4

57.5

59.1

56.8

50.0

42.6

NBS Abrasion Index

70

52

108

146

203

247

70

73

Yerzley Resilience, %

67

Too Low

55

58

65

75

60

Too Low

Clash Berg Torsional Stiffness

T-10,000 [68.9 MPa] C

23

21

21

26

25

17

Brittlepoint, C

37

35

33

33

37

32

14

Aged Volume Change, %

ASTM #1 Oil, 70 hr at 121C
IRM903 Oil, 70 hr at 121C
In water, 7 days at 70C

4
92
71

12
13
52

11
52
78

12
45
74

13
38
67

10
103
47

16
135
60

12
13
56

Compression Set, Method B, %

Cure: 35 min at 153C
22 hr at 70C

60

69

59

59

54

47

46

65

Stock Properties

Vulcanizate Properties
Cured 30 min at 153C

Maglite D was used

Suprex Clay was used
c
Sundex 790 was used
d
Hercules PE-200 was used
b

11

Unvulcanized Applications

Uncured compounds based on Hypalon 48 have

physical properties similar to those obtained with
uncured Hypalon 45. In applications for uncured
stocks, Hypalon 48 will impart greater oil and flame
resistance than Hypalon 45 in comparable compositions, but at a sacrifice in low temperature utility.
(See Table 7).

Hypalon 45 can also be compounded to give remarkably good stress/strain properties in uncured stocks.
These compounds may be used in applications such as
cove base, magnetic door closures, roofing membranes, and pond and pit liners. Hypalon 45 complies
with the Food and Drug Administration regulation
21 CFR 177.2210-Ethylene polymer chlorosulfonated. This regulation covers compounds of
Hypalon 45, which may be safely used in contact
with water used for drinking purposes.

Table 7
Uncured Properties of Hypalon 45 and Hypalon 48
Hypalon (type shown)
Magnesia (high activity)a
N990 Carbon Black
Polyethylene Glycolb

100
4
100
1.5

Type of Hypalon

Hypalon 45

Hypalon 48

49

Stock Properties
Mooney Viscosity,
ML 1 + 4 at 100C
Film Properties, uncured
0.76 mm (30 mil) calendered film
At RT

At 50C

At RT

At 50C

Original Physicals
100% Modulus, MPa
Maximum Strength, MPa
Elongation, %
Hardness, Durometer A

5.3
8.6
345
85

1.8
2.8
650
74

5.2
7.4
510
89

1.2
500
82

Tear Strength, Die C

kN/m

52.2

21.2

Cold Bend, 3.18 mm [1/8 in] Mandrel, 3.1 rad [180] Bend
At 34C
Brittleness Temperature C
Aged 168 hr at 50C in IRM903 Oil
Volume Change, %
a

Maglite D was used.

Carbowax 3350 was used.

12

Passed

Failed

50

+160

+16

Acid Acceptors

Compounding Ingredient Functions

The high reactivity of the sulfonyl chloride crosslinking sites in Hypalon synthetic rubber allows a
wide choice of practical curing systems. The basic
cross-linking system consists of a metal oxide combined with a sulfur-containing rubber accelerator or
with a peroxide and coagent. Calcium hydroxide with
HVA-2 and a coagent can also be used as a crosslinking system.

Ingredients
Normally Recommended

Function
Acid Acceptor

Hydrotalcite
Magnesia (High Activity)
Epoxy Resin of Epoxidized Oil
Calcium Hydroxide

Metal oxides act both as cross-linking agents and acid

acceptors in the curing of chlorosulfonated polyethylene. Magnesia and hydrotalcite are most commonly
used. Zinc oxide is undesirable and not recommended because degradation reactions catalyzed by
the formation of zinc chloride cause poor weathering
and heat aging. The choice of metal oxide is particularly important to vulcanizate properties.

Carbon Black
Titanium Dioxide
Organic & Inorganic Pigments

Colorants

Carbon Black
Mineral
Cork
Magnetic Filler

Filler

Antimony Oxide
Hydrated Alumina
Halogenated Hydrocarbons

More detailed information on acid acceptors can be

found in DuPont Dow Elastomers technical bulletin
Selecting a Cure System.

Petroleum

Petroleum Oils
Aromatic
Naphthenic

Synthetic

Esters
Chlorinated Paraffins
Polymeric
Polyesters

Magnesia-based acid acceptor systems are used

when colorability is desired. They are low cost,
provide good processing safety, and give vulcanizates
with better elongation than is obtained with litharge
systems. The magnesia system is suggested for
general use, particularly when water, chemical, and
compression set resistance are not critical properties.
High activity magnesias are preferred and should be
kept dry because exposure to atmospheric moisture
can cause a considerable loss in activity. Dispersions
of magnesia are available commercially that are
generally easier to handle and mix than powdered
magnesia.

Flame Retardant

Plasticizer

Processing Aids

SulfurBearing
Vulcanizing
Agentsa
Nonsulfur

Waxes
Stearic Acid
Low Mol. Wt. Polyethylene
Polyethylene Glycol
Fatty Acid Amides
Nordel IP 4770 or cis-4 PBD
Tackifiers

A lower level of magnesia can be used when it

is combined with primary polyols, such as
pentaerythritol. This combination reduces compound
viscosity, increases long-term storage time, and
improves heat resistance.

TMTD (or TETD)

Sulfur
Tetrone A
MBTS
NBC
DOTG

Hydrotalcites are used to provide improved water

and heat resistance compared to magnesia acid
acceptors. Hydrotalcites produce compounds with
good states of cure with good modulus values and
lower compressions sets. In soft compounds,
hydrotalcites can produce some porosity. If porosity
occurs, a calcined hydrotalcite product should be used.

Peroxide plus a coagent

HVA-2 plus a coagent

Epoxy resins may be used alone or combined with

magnesia to give water resistant vulcanizates suitable
for colored applications. Vulcanizates have high
elongation and low modulus.

For some applications, no vulcanizing agent is used.

13

Specific details on compounding and physical

properties of typical vulcanizates are available in
DuPont Dow Elastomers technical bulletin Selecting
A Filler.

Litharge or organic lead bases are sometimes used for

resistance to water when hydrotalcites do not provide
the required resistance. Litharge is used to meet wet
electrical properties in wire and cable applications. Due
to the hazards associated with lead oxides and leadbased products, it is recommended that the
masterbatch form of the product be used.

Flame Retardants

Calcium hydroxide can be used in combination

with HVA-2 curing agent and an amine coagent
for vulcanizates with excellent compression set
resistance.

Vulcanizates of Hypalon are generally more flame

resistant than hydrocarbon elastomer compositions by
virtue of their chlorine content. Flame resistance, as
judged by limiting oxygen index,* can be improved
through the addition of antimony oxide, hydrated
alumina and halogenated hydrocarbons.

Colorants

Plasticizers

For black vulcanizates of Hypalon, carbon black may

serve in the dual role of a colorant and filler. Black
stocks are more versatile from a compounding standpoint in that they can utilize either litharge or magnesia
based curing systems.

The selection of a plasticizer for use in Hypalon

depends on such factors as compatibility, processing
requirements, cost, and desired vulcanizate properties.
Aromatic petroleum oils are used extensively, primarily because of their low cost and compatibility. Ester
plasticizers are frequently used because of their light
color and good low-temperature properties. Chlorinated paraffin plasticizers give vulcanizates with good
flame resistance and weatherability. They are essentially colorless and non-discoloring upon exposure.

As discussed in the subsequent section on fillers,

magnesia based systems must be used where nonblack stocks are required. Litharge based systems
form lead sulfide which discolors the vulcanizate.
White vulcanizates are obtained by using titanium
dioxide. In addition to having high opacity and brightness, titanium dioxide serves as an ultraviolet screening agent when needed for outdoor weathering. A
number of organic and inorganic pigments recommended for Hypalon are given in DuPont Dow
Elastomers technical bulletin Compounding Hypalon
for Weather Resistance.

Polymeric plasticizers find use in Hypalon because

of their permanence or low volatility at elevated
temperatures. Since they are relatively high in cost,
they are usually used in compounds designed for
maximum heat resistance. Specific details for
selecting a plasticizer are available in DuPont Dow
Elastomers technical bulletin Selecting A Plasticizer
and Processing Aids.

Fillers

Processing Aids

Gum vulcanizates of Hypalon 40 have excellent

tensile strength, hence it is not necessary to use highly
reinforcing fillers to obtain high quality vulcanizates.

Processing aids are used in Hypalon to minimize mill

and calender roll sticking, improve release from
internal mixers, and improve extrudability. Microcrystalline waxes are effective release agents and are
widely used in Hypalon because of their good
solubility. Petrolatum, low molecular weight polyethylene and paraffinic waxes are also effective, but must
be used sparinglyused in excess, they bloom.

Fillers are often added to Hypalon for reasons of

economy. Carbon black is the preferred filler for
maximum physical strength and chemical resistance.
SRF carbon black gives a good balance of properties
and is widely used as a general purpose filler.

Green strength, for easier handling, can be achieved

by adding Nordel IP 4770 hydrocarbon rubber or
cis-4-polybutadiene; Nordel IP 4770 is especially
effective in mineral filled stocks of Hypalon. Fatty
acid amides are good anti-blocking agents for calendered sheet. When tack is necessary for building
operations, heat, solvents, or coumarone indene resin
should be evaluated.

For mineral filled vulcanizates, the filler selection

depends on the properties desired. No one particular
mineral filler can be suggested for general use.
Compared to carbon blacks, most mineral fillers impart
higher elongation and better resistance to tear, but
lower modulus, tensile strength, and resistance to
water and abrasion.
Cork is sometimes used as a filler and results in a
cork/elastomeric composition having good oil, heat and
set resistance. Another specialty composition uses
ferrite as a filler, yielding an elastomeric product
which can be converted to a flexible magnet.

* Values measured by this test are not intended to reflect hazards

of this or any other material under actual fire conditions. DuPont
Dow Elastomers technical bulletin Selecting A Plasticizer and
Processing Aid, gives the preferred materials for achieving desired
physical properties in vulcanizates of Hypalon.

14

Vulcanizing Agents*

Abbreviated Chemical Names

The acid acceptors, such as magnesia function as

crosslinking agents (in addition to acting as HCl
scavengers), and as such can be considered vulcanizing agents. However, the cure rate and cure state of
compounds of Hypalon can be greatly improved
through the use of organic vulcanizing agents and
accelerators. Vulcanizing agents for Hypalon can be
classified or grouped into two categoriessulfur
bearing agents and non-sulfur bearing agents. (See
DuPont Dow Elastomers technical bulletin Selecting
A Curing System.)

In many places throughout this technical information

we have, for convenience, used abbreviations for the
chemical names of the curatives discussed. In most
cases, the abbreviations are familiar forms used
throughout the rubber industry. Listed below are the
abbreviations used and the full chemical name of the
material.
Abbreviation
DOTG
MBT
NBC
TETD
TMTD

Sulfur-Bearing Systems
A combination of magnesium oxide and pentaerythritol,
TMTD, and sulfur is considered to be a good general
purpose curing system for black products. This
combination provides good processing safety and gives
vulcanizates with a high state of cure, good compression set resistance, good heat and chemical resistance.
The rate of cure can be increased, as judged by
modulus values, by substituting either TETD/sulfur or
Tetrone A/MBTS for TMTD/ sulfur.

Chemical Name
Di-ortho-tolyl guanidine
2 mercaptobenzothiazyl disulfide
Nickeldibutyl dithiocarbamate
Tetraethyl thiuram disulfide
Tetramethyl thiuram disulfide

Polymer Processing Characteristics

Uncured Hypalon synthetic rubber is more thermoplastic than other commonly used elastomers. It is
generally tougher at room temperature, but softens
more rapidly as temperature is increased. Viscosity
temperature relationships for Hypalon 40 and SBR
are shown in Figure 2.

Vulcanizate resistance to heat degradation is also

improved; however, these systems are more expensive and give less processing safety.

Figure 2.

The addition of NBC to any of the sulfur bearing

systems will significantly improve resistance to heat
degradation, but reduces processing safety.

Viscosity-Temperature Relationship of
Hypalon 40 and SBR 1500

Non Sulfur Bearing Systems

70

Basically, there are two types of non-sulfur cure

systems, both of which provide good processing safety
and compression set resistance. The first is a peroxide
system, and the other a maleimide system which
utilizes HVA-2 from DuPont Dow Elastomers.

Temperature, C
130
100

Mooney Viscosity, ML 1 + 4

150

The peroxide system requires an alkaline medium,

which can be provided by use of a high level of
magnesia in combination with neutral or basic fillers.
Coagents like triallyl-cyanurate (TAC) are used with
peroxides to increase crosslink yield and obtain a
satisfactory rate and/or state of cure.
In maleimide systems, HVA-2 is the primary curing
agent. Calcium hydroxide is used as the acid acceptor,
and amines are added as cure activators.

100
90
80
70
60
50
40
30

20

These alternate systems are described in detail in

DuPont Dow Elastomers technical bulletin Selecting
A Curing System.

15

*For some applications, no vulcanizing agent or accelerator is used.

15

Hypalon 40

SBR 1500

The low viscosity of Hypalon 40 at elevated temperatures permits extrusions that are low in die swell,
smooth at fast extrusion rates, and sharply defined,
especially at thin edges. This softness under slightly
warmed conditions (40C) makes building operations
practical, giving good ply adhesion and knitting without
the use of tackifiers. However, because of this same
softness, immediate cooling of extrusions is necessary
to prevent distortion. The high viscosity of Hypalon
40 at low temperatures makes it necessary to warm
stocks before extruding or calendering for more
uniform results. Variations in stock temperature cause
variable extrusion rates and calendered sheet with
uneven gauge and a rough surface.

Figure 3. Viscosity-Temperature Relationship of

Hypalon Polymers

70

Temperature, C
130
100

400

Mooney Viscosity, ML 1 + 4

300

Processing of either very soft or very stiff compounds

can be improved by using one of the other grades of
Hypalon 40. The high viscosities of Hypalon 4085
and Hypalon 6525 help eliminate trapped air and
blistering during processing and curing of highly
extended or low durometer stocks. They also help
minimize distortion of these compounds after extrusion
and during open steam curing. The low viscosities
of 40S permit easier processing of stocks containing
highly reinforcing fillers or small amounts of
plasticizers.

200

100
90
80
70
60
50
40
30
20

10

Viscosity temperature curves for these polymers and

Hypalon 45 and 48 are shown in Figure 3. Note that
Hypalon 45 and 48 are more temperature sensitive
than any of the Hypalon 40 types.
For additional information, see DuPont Dow
Elastomers technical bulletin, Processing Hypalon.

16

AHypalon 4085
BHypalon 48
CHypalon 40
DHypalon 40S
EHypalon 45

A
B
C
D
E

Proprietary Materials

Proprietary compounding ingredients mentioned in this bulletin are listed below. This is not to imply that
comparable ingredients from other sources might not be equally satisfactory.
Product Name

Composition

Supplier

Hypalon Synthetic Rubber

Chlorosulfonated polyethylene

HVA-2 Curing Agent

N, N-m-phenylenedimaleimide

Nordel IP Hydrocarbon Rubber

EPDM

Tetrone A Rubber Accelerator

Dipentamethylene thiuram
tetrasulfide

Carbowax

Polyethylene glycol of
approximately 3350 MW

The Dow Chemical Co.

Midland, MI

Harmony Oil No. 46

Petroleum-base fluid

Gulf Oil Company-U.S.

Houston, TX

Hercules PE-200
Pentaerythritol

Fine particle size technical

pentaerythritol200 mesh

Hercules, Inc.
Wilmington, DE

Maglite D

High activity magnesium oxide

Marine Magnesium Co.

Coraopolis, PA

Sundex 790 Aromatic Oil

Aromatic hydrocarbon process oil

Sun Petroleum Products Co.

Philadelphia, PA

Suprex Clay

Kaolin clay

J. M. Huber Corporation
Macon, GA

Vanox NBC

Nickel dibutyl dithiocarbonate

Varox DBPH-50

2,5 dimethy 2,5 di (t-butylperoxy)

hexane

Vanwax H

Microcystalline wax

17

DuPont Dow Elastomers

Wilmington, DE

R. T. Vanderbilt Company
Norwalk, CT

For further information on Hypalon or other elastomers please contact one of the addresses below, or
visit us at our website at www.dupont-dow.com
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Tel. +65-6275 9383
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Austria

Finland

Dolder GmbH
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Tel. +43-1-504 21 80
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Oy Algol AB
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Tel. +358-3-266 1948
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Benelux

France

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19, av. des Nnuphars
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DuPont Dow Elastomers GmbH

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Nordica Elastomers AB
Hamntorget 1
P.O. Box 10104
S-43422 Kungsbacka
Tel. +46-300-73 250
Fax +46-300-73 251

Portugal
Safic-Alcan Portugal Lda.
Rua D. Marcos da Cruz 1351
P-4455-482 Perafita
Tel. +351-22-999 82 90
Fax +351-22-996 39 27

Japan
DuPont Dow Elastomers Ltd.
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Shinagawa-ku
Tokyo, Japan 141-0022
Tel. +81-3-3444-5166
Fax +81-3-3444-6095

Safic-Alcan Espana, S.A.

Division Isisa
Rocafort, 241-243
E-08029 Barcelona
Tel. +34-93-322 04 53
Fax +34-93-410 69 78

Italy
Dolder-Massara
Via Cadutti Bollatesi 38/b
20021 Bollate (MI) Italy
Tel. +39-02-350081
Fax +39-02-38300725

Switzerland
Dolder AG
Immengasse 9
CH-4004 Basel
Tel. +41-61-326 66 00
Fax +41-61-326 62 04

The information set forth herein is furnished free of charge and is based on technical data that DuPont Dow Elastomers believes to be reliable. It is intended for use by persons having
technical skill, at their own discretion and risk. Handling precaution information is given with the understanding that those using it will satisfy themselves that their particular conditions
of use present no health or safety hazards. Since conditions of product use and disposal are outside of our control, we make no warranties, express or implied, and assume no liability
in connection with any use of this information. As with any material, evaluation of any compound under end-use conditions prior to specification is essential. Nothing herein is to be
taken as a license to operate or a recommendation to infringe on any patents. While the information presented here is accurate at the time of publication, specifications can change. Please
check www.dupont-dow.com for the most up-to-date information.
Caution: Do not use in medical applications involving permanent implantation in the human body. For other medical applications, discuss with your DuPont Dow Elastomers customer
service representative and read Medical Caution Statement H-69237-01.
Hypalon, Nordel, and Tetrone A are registered trademarks of DuPont Dow Elastomers.
Copyright 1997, 2001, 2002 DuPont Dow Elastomers. All rights reserved.

(11/02) Printed in U.S.A.

Reorder No.: HPE-H68577-00-D1102